Mercedes Coupes/Sedans/Wagons 1974-1984 Repair Guide

Transmission Assembly

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REMOVAL & INSTALLATION



The transmission should only be removed with the engine as a unit. The transmission-to-bell housing bolts can only be reached from inside. Once the engine/transmission unit has been removed from the vehicle, the transmission and bell housing must be separated from the engine, as follows:

With Engine

ALL MODELS
  1. Refer to Engine And Engine Rebuilding to remove the engine/transmission.
  2.  
  3. After removing the engine/transmission unit, unbolt the bellhousing from the engine. The bolts which hold the transmission to the bellhousing cannot be reached except from inside the bell housing.
  4.  
  5. Remove the starter. Pull the transmission and bellhousing from the engine.
  6.  
  7. The bolts which secure the bellhousing to the transmission are now visible and can be removed to separate the bellhousing and transmission.
  8.  

To install:
  1. Connect the engine, bellhousing, and transmission, after coating the splines of the mainshaft with grease.
  2.  
  3. Install the starter.
  4.  
  5. Further installation is the reverse of removal.
  6.  

Without Engine

1974-81 240D MODELS
  1. Support the car on jackstands.
  2.  
  3. Disconnect the battery.
  4.  
  5. Disconnect the exhaust pipe and/or muffler to provide clearance around the bellhousing.
  6.  
  7. Unhook the slave cylinder hydraulic line at the connection and plug both openings.
  8.  
  9. Unbolt the rear engine mount.
  10.  
  11. Slightly raise the transmission with a jack and remove the lower plate covering the transmission tunnel.
  12.  
  13. Disconnect the speedometer cable from the rear of the transmission.
  14.  
  15. Disconnect the shift rods from the transmission shift levers.
  16.  
  17. Loosen, but do not remove, the intermediate bearing bolts.
  18.  
  19. Matchmark the U-joint and driveshaft coupling and loosen the U-joint.
  20.  
  21. Matchmark the driveshaft flange and adaptor. Loosen the 3 driveshaft bolts. Remove 2 of the bolts and pivot the driveshaft around enough to reinstall the 2 bolts. Remove the 3rd bolt and position the driveshaft rearward as far as the center bearing permits. Use a piece of wood to block the driveshaft up in the driveshaft tunnel. Reinstall the 3rd bolt. The adaptor plate should remain on the 3-legged transmission flange.
  22.  
  23. Remove the starter.
  24.  
  25. Remove all bolts attaching the transmission to the intermediate flange, but remove the upper 2 bolts last.
  26.  

The clutch housing is heavily ribbed. Because of this, most of the bolts can only be reached with a 17 or 19 mm insert and extension.

  1. Turn the transmission 45- to the left so that the starter domes on both sides of the clutch housing do not scrape the transmission tunnel.
  2.  
  3. Keep the transmission level and slide it out.
  4.  
  5. The clutch housing bolts can only be reached from inside. Unbolt the housing and remove it.
  6.  
  7. Installation is the reverse of removal.
  8.  

1982-83 240D MODELS
  1. Disconnect the battery.
  2.  
  3. Disconnect the regulating shaft in the engine compartment.
  4.  
  5. Support the transmission with a floor jack.
  6.  
  7. Unbolt the rear engine mount.
  8.  
  9. Unbolt each side of the engine carrier on the floor frame.
  10.  
  11. Unscrew the exhaust mounting bracket on the transmission. Note the number and positioning of all washers.
  12.  
  13. Unbolt the retaining strap and remove the exhaust pipe bracket.
  14.  
  15. Loosen the clamp nut on the driveshaft.
  16.  
  17. Loosen, but do not remove, the intermediate bearing bolts.
  18.  
  19. Unbolt the driveshaft on the transmission so that the companion plate remains with the driveshaft.
  20.  
  21. Carefully push the driveshaft as far to the rear as permitted.
  22.  
  23. Loosen and remove the tachometer drive shaft on the rear transmission case cover. Unclip the clip for the tachometer drive shaft from its holder.
  24.  
  25. Unscrew the holder for the line to the clutch housing. Unscrew the clutch slave cylinder and move it toward the rear until the pushrod is clear of the housing.
  26.  
  27. Push off the clip locks and then remove the shift rods from the intermediate levers on the shift bracket. Note the position of the disc springs.
  28.  


WARNING
When the shift rods are disconnected, do not move the shift lever into reverse or you risk damaging the back-up light switch.

  1. Unbolt the starter and remove it.
  2.  
  3. Remove all transmission-to-intermediate flange screws. Remove the upper two last.
  4.  
  5. Carefully pull the transmission toward the rear of the vehicle and then remove it downward.
  6.  

Make sure that the input shaft has cleared the clutch plate before tilting the transmission.

To install:
  1. Lightly grease the centering lug and splines on the transmission input shaft.
  2.  

Position the clutch slave cylinder and line above the transmission before beginning installation.

  1. Move the transmission into the clutch so that one gear step engages. Rotate the mainshaft back and forth until the splines on the input shaft and clutch plate are aligned.
  2.  
  3. Move the transmission all the way in and then tighten the transmission-to-intermediate flange screws.
  4.  
  5. Install the starter.
  6.  
  7. Install the clutch slave cylinder with the proper plastic shims.
  8.  
  9. Installation of the remaining components is in the reverse order of removal. Please note the following:
    1. After installing the driveshaft, roll the car back and forth and then tighten the intermediate bearing free of tension.
    2.  
    3. Tighten the driveshaft clamp nut to 22-29 ft. lbs. (30-40 Nm).
    4.  
    5. Make sure of the proper positioning of all washers, spacers and shims.
    6.  

  10.  

190D AND 190E MODELS
  1. Disconnect the battery.
  2.  
  3. Cover the insulation mat in the engine compartment to prevent damage.
  4.  
  5. On vehicles equipped with a auxiliary heater, be sure that the water hose is out of the way.
  6.  
  7. Support the transmission with a floor jack.
  8.  
  9. Unbolt the engine mounts at the rear transmission cover.
  10.  
  11. Unbolt the engine carrier on the floor frame.
  12.  
  13. Unscrew the exhaust holder at the transmission. Note the number and positioning of all washers.
  14.  
  15. Unscrew the clamping strap and remove the exhaust pipe holder.
  16.  
  17. Remove the intermediate bearing shield plate.
  18.  
  19. Repeat Steps 8-11 of the 1982-83 240D procedure.
  20.  

On the 190E, the fitted sleeves on the universal flange must be loosened before separating the flange from the companion plate. This will require a cylindrical mandrel.

  1. Disconnect the exhaust system at the rear suspension and suspend it with wire.
  2.  
  3. Loosen and remove the input shaft for the tachometer.
  4.  
  5. Repeat Steps 12-16 of the 1982-83 240D procedure.
  6.  
  7. Rotate the transmission approximately 45- to the left, slide it out of the clutch plate and then remove it downward.
  8.  

Make sure that the input shaft has cleared the clutch plate before tilting the transmission.

  1. To install, repeat Steps 18-23 of the 1982-83 240D procedure. Remember that the transmission must be tilted approximately 45- to the left when installing.
  2.  

 
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